What kind of tools do you have laying around? A drill press? Lathe? Plane? Wood chisel? Scribe? Drill? Scroll saw/skill saw?
You'll need em.
Materials: PVC tube with .357 inch diameter inside measurement (or something close. 1/2 inch works too). Wood that is about 3/4 inch thick, or thicker, depending on the outside diameter of your tube. A block about two inches across, or a two inch diameter dowel rod.
Start with the cylinder. Either cut a block to the right length and lathe it round, or use a dowel rod and cut it where you need it. Mark the round wood piece on the flat end, dividing it up in to six sections. In the middle of the section, near the edge of the block, drill a .45 inch diameter hole (or a hole that is the same diameter as the inside of your PVC barrel) all the way though. Use the wood chisel to carve out the rounded depressions in the cylinder between the chambers. (use a picture as a guide).
Cut the shape of the frame, thats every part of the gun thats not the barrel or the cylinder. Inlcude the trigger guard, and the hammer if you'd like. Cut a hold in the middle of the frame piece thats large enough to admit the cylinder. Center the cylinder and glue it in place. Attach the tube to the frame, and attach the spring housing below that. Use a strip of your wood across the top to make the accessory bar, then sand and paint.
Thats about as quick and dirty as it can be made and still look good.
Adding detail is where this piece will shine. If its just for holster fill, then you may need to add some rounded bits of wood for the grips, and maybe detail the hammer a bit. If you're going to be waving it around, then the more detail the better.
Make it a point to paint the end of the barrel orange, and get to know the con security people. Let them know you have a prop weapon and show it to them. Ask permission before you bring it on the con floor. If they say no, then leave it in your room or bag. Thats the only bad part about making realistic prop weapons. Not many places will let you carry them.
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The Tentacle Guy
Disclaimer: Management not responsible for any injuries, loss of life, fiduciary burden, loss of virginity, loss of sanity, lack of morals, or gross changes in appearance.
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